Electronically-Actuated Cementing Port Collar for Staged Operations
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Solution Overview
Problem
Current cementing operations in wellbores face challenges such as cement flow into weak earth formations and difficulty in ensuring complete annulus cementation, particularly in staged cementing applications where mechanical port collars require complex operations and precise location of shifting tools.
Innovation Solution
An electronically-actuated port collar with biased sleeves and restraints, activated by RFID tags or timing, allows for automatic opening and closing of exit ports for cement slurry flow, eliminating the need for mechanical manipulation and precise tool location, and includes a controller for triggering these actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical port collars are used for staged cementing operations, then cement placement can be controlled at specific locations, but the operation becomes complex and requires precise location of shifting tools
Solution Approach 1:
The patent replaces the mechanical shifting tool system with an electronically actuated valve system. The valve is controlled by electronic signals received from surface equipment, eliminating the need for mechanical manipulation of port collars and associated shifting tools. This substitution resolves the contradiction by removing the complexity of precise mechanical location while maintaining controlled cement placement capability through electronic actuation.
Solution Approach 2:
The patent introduces an electronic controller as an intermediary between the cementing operation and the valve actuation mechanism. This controller receives signals from surface equipment and translates them into appropriate valve actuation commands, serving as a mediator that eliminates the need for direct mechanical connection and precise tool positioning while maintaining controlled cement flow.
2Reliability
If mechanical shifting tools are used to operate port collars, then cement flow can be controlled, but extra rig time is required to run and retrieve the workstring
Solution Approach 1:
The patent replaces the mechanical workstring-based control system with an electronic control system that can be actuated from the surface without requiring the running and retrieval of specialized shifting tools. The electronically actuated valve maintains reliable cement flow control while eliminating the time-consuming mechanical operation of running and retrieving workstrings with shifting tools.
Solution Approach 2:
The valve is pre-installed on the casing string during the initial run, with its actuation mechanism already in place and ready for electronic control. This preliminary installation eliminates the need for subsequent mechanical intervention with shifting tools, allowing cement flow control to be achieved simply by sending electronic actuation signals from the surface.
3Adaptability or versatility
If stage tools are run above packers for staged cementing, then cement can be placed in specific zones, but the assembly becomes more complex with multiple components
Solution Approach 1:
The patent merges the stage tool functionality directly into the port collar assembly, creating an integrated unit that combines cement placement control with the casing connection function. This integration eliminates the need for separate stage tools and packers in many configurations, reducing assembly complexity while maintaining the capability for staged cementing operations through electronically controlled valve actuation.
Solution Approach 2:
The electronically actuated port collar serves multiple functions: it acts as a connection element for the casing string, a control valve for cement flow, and a stage tool for zoned cementing. This multi-functionality eliminates the need for multiple separate components, reducing assembly complexity while maintaining adaptability for various staged cementing scenarios.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the time and complexity of opening and closing the port collar, ensuring efficient cement placement and setting without the need for running an inner string, and allows for reliable operation in deviated holes without requiring precise mechanical manipulation.
Implementation Method 1
The opening sleeve (120) has a biasing member or spring (122) that wants to shift the sleeve open
Implementation Method 2
The actuator (206) can be an electronic fuse that burns through a restraint (126)
Implementation Method 3
The controller (200) can be actuated using various techniques including the use of radio frequency identification (RFID) tags
Data Source
Figure 1A~1B
Figure 2~3
Figure 4A~4B
AI summary
A cementing port collar (100) has an opening sleeve (120) biased from a closed position to an opened position relative to the collar's exit port (115), and a first restraint (126) temporarily holds the opening sleeve closed. The collar also has a closing sleeve (140) biased from an opened position to a closed position, and a second restraint (146) temporarily holds the closing sleeve opened. During cementing, the first restraint is electronically activated with a first trigger to release the opening sleeve opened so cement slurry can pass out of the collar's exit port to the borehole annulus. When cementing is completed, the second restraint is electronically activated with a second trigger to release the closing sleeve closed to close off the collar to the borehole so the cement can set. The restraints can include bands of synthetic fiber, which are burned by fuses activated by a controller of the collar responding to passage of RFID tags.